Conductor rail for supplying power and a production method therefor

ABSTRACT

The invention relates to a conductor rail for supplying power to current consumers. The inventive conductor rail is comprised of a base body ( 1 ) and of a slide surface ( 2   a ) which is connected to the base body ( 1 ) and which is made of an especially wear-resistant material. Connecting elements ( 5 ) extending over the length of the slide surface ( 2 ) are provided on the side of the part ( 2 ) which forms the slide surface ( 2   a ); said side pointing toward the base body ( 1 ). Each connecting element ( 5 ) together with an elongated narrow side ( 2   b ) of the slide surface part ( 2 ), forms a recess ( 3 ). The recess is at least partially filled with the material ( 6 ) of the base body ( 1 ).

CROSS REFERENCE TO RELATED APPLICATIONS

This Application claims the priority of German Patent Application SerialNumber 198.46.491.6, filed Oct. 9, 1999 and International PatentApplication Serial Number PCT/EP99/07575 having an international filingdate of Oct. 8, 1999 the entire contents of both of which areincorporated rein by reference.

BACKGROUND OF THE INVENTION

1. Field of Invention

The invention relates to a current conducting rail.

2. Description of Related Art

Current conducting rails for supplying of mobile consumers that arecomprised of two different materials are known in the art in numerousembodiments. Said conductor rails are comprised mainly of a base bodyonto which a sliding surface comprised of especially wear-resistantmetal is applied. The German utility model 7114522 demonstrates such aconductor rail comprised of a base body made of metal which exhibits ahead in which the sliding surface is folded around the head of the basebody.

DT 2349127 discloses to the art a conductor rail for current consumerswith high current demand and high travel speed, which exhibits aconnector on the side facing the base body and which exhibits undercuts.The sliding surface body together with its contact is inserted at thenarrow facial surface of the base into a corresponding groove in thebase body that corresponds to the contact. Thereupon the external limbsof the sliding surface are bent against the corresponding sides of thebase body using rollers acting upon them. At the same time the sides ofthe groove of the base body are pressed against the connector such thata permanent connection between the sliding surface and the base body iscreated.

Similarly, the German patent 2244452 discloses a current rail for thesupply of current to movable current consumers with high currentrequirements and high speeds in which a slide surface comprised of aparticularly wear-resistance metal is arranged on the base body. Thebase body exhibits on its side facing the slide surface a number ofdove-tail projections over the length of the base body whereby saidprojections are engaged by U-shaped recesses in the web of the basebody, whose flanks are engaged against the corresponding flanks of theprojections on the base body. In the joining process, using rollers,which on the one hand presses together the slide surface serving as thecurrent collector and the lateral wall of the base body to be joinedwith the slide rail, whereby the walls of the contact situated in theU-shaped recesses of the slide rail are pressed against thecorresponding dove-tailed projections. At the same time the outerconnecting pieces of the slide rail are engaged against the flanks ofthe base body in the customary manner using rollers.

The disadvantage in the current rails described in the foregoing is thatthe slide current conductor material which is always harder than that ofthe base body, is deformed, whereby there is no optimal adaptation canbe produced between the softer material of the base body and the currentconductor material at the time of roller shaping. Due to the fact thatthe current conductor, especially at its outer surfaces, does notoptimally lie on the base body material, moisture can intrude betweenthe two parts.

SUMMARY OF THE INVENTION

The purpose of the invention is to provide a current rail with awear-resistant slide surface that is applied mechanically to the softerbase body and in which corrosion does not form between the base body andthe slide surface.

This purpose is achieved by a current rail having the characteristicsdescribed in claim 1. The current rail described in the invention ischaracterized by the fact that generally the softer material of the basebody deforms and consequently a better connection between base body andslide surface is established. Corrosion formation, which could occur incurrent rails after the current state of technology whereby moisturefrom outside could at any time intrude between the base body and theslide surface laterally into the current rail is confronted in that thesofter material of the base body, which is made especially of aluminum,is in cross-section is securely rolled onto the external surface or theoutside edge of the harder slide surface piece. If, in the case ofconventional current rails the base body is laterally wrapped by theharder slide surface material, then in the solution provided by theinstant invention the softer material of the base body is pressed ontothe harder material of the slide surface.

In order to achieve an optimum fastening between the structures of thebase body and slide surface, connecting pieces are formed along thecurrent rail at the slide surface that are especially provided withback-cuts. In the joining process the softer material of the base bodyis pressed behind the back-cuts, whereby a durable connection betweenbase body and slide surface is achieved.

An advantageous connection between the base body and the slide surfaceis achieved especially when the base body is made of aluminum and theslide surface is made of stainless steel or copper. The forming of thealuminum base body is advantageously applied in the application in whicheven a light cold-hardening, but no embrittlement of the aluminumoccurs.

In one possible embodiment, all connecting pieces have back-cuts only onone side. On the side of the connecting pieces facing the back-cutsthere are slightly conical surfaces with an slope angle of about twodegrees. On the side of the base body facing the slide surface structurea plurality of recesses are provided into which the connecting piecesengage prior to the forming process. The recesses are formed slightlyconical, whereby the aperture cross-section is larger than the floorcross-section. The aperture angle of the conically arranged side wallslikewise are approximately two degrees.

The inside surfaces of the longitudinal recess exhibit in a preferredembodiment longitudinal grooves. Inasmuch as an aluminum structure isused as the base body, a micrometer thin oxide layer always develops. Bysaid grooving said oxidation layer is removed during the joiningprocess, whereby a very satisfactory electrical contact is establishedbetween the base body and the slide surface. It is of further advantageif the connecting pieces have a greater peak-to-valley height than theslide surface itself, whereby a very satisfactory bond between the basebody and the slide surface material is produced.

For the joining process a roller presses the slide surface materialagainst the base body. A profiled roller presses at the same time thebase body against the slide surface structure. In this way, theconnecting pieces are pressed into the recesses , whereby the conicalsurfaces of the recesses and the connecting pieces are compressedagainst each other. Due to the compression pressure the grooving deformsand adapts to the contour of the shape of the connecting pieces. In theprocess, the oxidation layer of the aluminum structure is pulled away inthe area of the grooving. Another spontaneous oxidation, which wouldproceed in a few minutes, is prevented by the satisfactory fit betweenthe base body and the slide surface.

In order that the base body material is pressed into the space behindthe back-cuts of the connecting pieces of the slide surface structure, aheavily profiled roll is used that is brought to rest on the side of thebase body facing away from the slide surface structure.

By means of additional rolls that provide a lateral pressure against thematerial of the base body, the material is pressed into the recessesfacing outward that are formed by the back-cuts of the outsideconnecting pieces and the long narrow sides of the slide surface. Thisprovides a smooth transition between the material of the base body andthat of the slide surface that prevents the intrusion of moisturebetween the two parts.

In order to prevent unnecessary additional tolerance, it is advantageousif the profiled parts, base body and slide surface, during theirextrusion production process, are provided with rolled-in grooves toassure uniform lateral alignment.

Since, in the inventive current rail it is also possible that moisturecan penetrate at the current rail end into the interspace between theslide surface and the base body, in a particular embodiment of theinvention a contact mass is introduced prior to the joining processbetween the base body structure and the slide surface structure for thepurpose of corrosion prevention, said mass is distributed in the joiningprocess evening and over the entire contact surface.

Subsequently, a possible exemplary embodiment of an current railaccording to the invention and its production method is described indetail in conjunction with the following drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a cross-sectional view of the assembled structural partsbase body and slide surface.

FIG. 2 depicts the production step in which the material of the basebody is compressed by means of a roll or pressure roller behind theback-cuts of the connecting pieces of the slide surface structure.

FIG. 3 depicts a cross-sectional view of an assembled current railaccording to the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 depicts the two extruded structures 1 and 2 which are compressedagainst each other by means of the rollers R1 and R2.

The base body 1 exhibits four recesses 4 extending longitudinally alongthe current rail, in which the connecting pieces 5 of the slide surfacestructure 2 are situated. The recesses 4 have conically shaped flanks,so that the aperture cross-section is larger than the cross-sectionalarea of the floor of the recesses 4. This provides for simplerpre-assembly of the base body 1 and slide surface structure 2. Theconnecting pieces 5 each exhibit back-cuts 5 a on one side.

By the action of the rollers R1, R2, and R3 the material of the basebody 1 is compressed and is forced behind the back-cuts 5 a of theconnecting pieces 5 and against the flanks connecting pieces.

The surface of the base body structure 1, which comes into contact withthe connecting pieces 5 during the joining process, exhibits in partlongitudinal grooving 7, which are also deformed during the joiningprocess. By deforming the grooving the oxide layer in said area pullsoff and the result is contact of non-oxidized base body material 7 awith the material of the slide surface profile 2.

For the purpose of compression of the base body 1 onto the slide surfacestructure 2 the roller or roll R2 exhibits a flat bearing or applicationface 9, which supports against the side 8 of the base body facing awayfrom the slide surface structure 2. The roller or roll R2 is profiledand exhibits in a simple embodiment a peripheral horn-shaped protrusion10, which compresses the material of the base body in such a way thatthe material in the region of the grooving 7 deforms. Using a secondroller R3, as depicted in FIG. 2, which is more heavily profiled thanroller R2, the material of the base body 1 is forced behind theback-cuts (reverse protrusions) 5 a of the connecting pieces 5. At thesame time the outer legs 6 are compressed using lateral pressure rollsor rollers R4 into the recesses 3, so that a smooth transition betweenthe base body 1 and the long narrow sides 2 b of the slide surfacestructure 3 results.

The hollow spaces 13 running longitudinally serve the purpose of savingmaterial and simultaneous increase of surface area of the base body 1.They can exhibit any cross-sectional shape, to take up heating from theends of the current rail into the hollow space 13.

As depicted in FIG. 3, the V-shaped recesses 14, 15 remain after thejoining process on the side 8 of the base body 1 facing away from theslide surface.

The longitudinal grooves 16, 17 which are produced in the base bodystructure 1 and in the slide surface structure 2 during the extrusionprocess, serve to simplify arrangement at the time or pre-assembly ofthe base body 1 and slide surface 2, so that unnecessary additionaltolerance by incorrect pre-assembly can be avoided.

Furthermore, the longitudinal grooves 16 and 17 of the finished currentrail serve in express lateral arrangement during the installation of thecurrent rail.

We claim:
 1. Current rails for supply of current to current consumerscomprising a base body (1) and a slide/contact surface (2 a) joined tothe base body (1) made of an especially wear-resistant material, wherebyon the part forming the slide/contact surface (2 a) facing the base body(1) connecting pieces (5) extending over the length of the slide/contactsurface are provided, and characterized by the fact that a connectingpiece (5) together with a long narrow side (2 b) of the slide/contactsurface (2) forms a recess (reverse protrusion) (3) on the outside edgeof said connecting piece (5), which recess is at least partially filledby the material (6) of the base body (1).
 2. A current rail according toclaim 1 and characterized by the fact that the base body (1) exhibits anumber of recesses (4) corresponding to the number of connecting pieces(5) into which the connecting pieces (5) are inserted and the walls ofthe recesses (4) are compressed by at least one deformation joiningprocess at the surfaces of the corresponding connecting pieces (5).
 3. Acurrent rail according to claim 2 characterized by the fact that atleast one of the connecting pieces (5) exhibits a back-cut (5 a) and therecess (4) brought into contact with the corresponding connecting piece(5) whose back-cut (5 a) grips around after the joining process.
 4. Acurrent rail according to claim 1 characterized by the fact that thesurface of the base body (1) exhibits at least segmentally grooving (7)in those areas that are pressed onto the surface of the connectingpieces (5) of the slide/contact surface part (2) during the joiningprocess.
 5. A current rail according to claim 4 and characterized by thefact that the base body (1) is made of aluminum, whereby prior to thejoining process an oxide layer forms on the surface of the base body (1)and the grooving (7) is so contrived that in the joining process saidoxidized layer is pulled off.
 6. A current rail according to claim 1characterized by the fact that the recesses (4) in the base body (1)prior to the forming process are generally U-shaped.
 7. A current railaccording to claim 1 characterized by the fact that the base body (1)exhibits at least one hollow space (13) extending over the length of thebase body (1) which serves to increase the surface area of the base body(1).
 8. A current rail according to claim 1 characterized by the factthat the base body (1) exhibits at least one channel (13) extending overthe length of the base body (1) in which there is at least segmentallyheating or through which a heating or cooling agent flows.
 9. A currentrail according to claim 1 characterized by the fact that the base body(1) is an extruded structure comprised of aluminum and the slide/contactsurface part (2) is an extruded structure comprised of stainless steel.10. A process for producing a current rail according to claim 1characterized by the following steps: a. in an initial process step theslide/contact surface part (2) is inserted by means of its connectingpieces (5) into the recesses (4) provided therefor, and b. in a secondprocess step using rollers the base body (1) and the slide/contactsurface part (2) are compressed together in such a manner that aninitial roller (R1) presses against the surface (2 a) serving as thecurrent collector surface and a second roller (R3) pressing base body(1), on the side of the base body facing away from the slide/contactsurface (2), against the slide/contact part (2) is profiled in such away that at least one of peripheral protrusions (10, 11, 12) protrudingfrom the roller surfaces (9) presses the material of the base bodybehind at least one back-cut (5 a) of a connecting piece (5) of theslide/contact piece (2), and c. at the same time in or after the secondprocess step b above, rollers (R4) compress the material (6) of the basebody (1) laterally from the outside and press said material behindback-cuts (5 a) of the recesses (reverse protrusions) (3) formed by theconnecting pieces (5) of the slide/contact part (2).
 11. A process forthe production of a current rail according to claim 10 and characterizedby the fact that in the side (8) of the base body (1) facing away fromthe slide/contact surface (2) a V-shaped notch is present for centeringa profiled roller (R2) and that prior to the second process step b, theroller (R2) which its contact face (9) compresses the base body (1) andthe slide/contact surface part (2) together.
 12. A process for theproduction of a current rail according to claim 11 and characterized bythe fact that when using a base body (1) made of aluminum, in whichspecific surface areas exhibit grooves (7), which come into contact withthe connecting pieces (5) of the slide/contact surface (2), at least theoxide layer is pulled off in the region of the grooves (7) at the timeof creating the V-shaped notch by the profiled roller (R2).